ULTRASONIC GENERATOR/POWER SUPPLY Auto-Plus MPC · This product’s rugged internal ultrasonic generator cir-cuitry ensures a continuous resonant frequency lock at the start of each

www.dukane.com

Dukane Part No. 403 - 608 - 00

iQ SeriesULTRASONIC GENERATOR/POWER SUPPLY

Auto-Plus MPC

User’s Manual

Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 - 4900

Dukane products are manufactured in ISO registered facilities

AUTOMATED PRESSHAND PROBE

http://www.dukane.com

Page ii

iQ Series, Auto-Plus MPC User’s Manual

Dukane Manual Part No. 403-608-00

Printed in the United States of America.

Dukane Part Number: 403-608-00

Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents:(* = Inactive)3,780,926 * 4,131,505* 4,277,710* 5,798,599 5,880,580 6,984,921 7,225,965 7,475,801, 7,819,158 and, 8,052,816

Copyright © 2019 Dukane 2900 Dukane Drive St. Charles, IL 60174 USA

Notice of Rights:All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieval system, without written permission from Dukane.

Notice of Liability:The information contained in this manual is distributed on an “As is” basis, without warranty. While every precaution has been taken in the preparation of this manual, Dukane shall not have any liability to any person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual, or by the hardware products described herein.

Specifications subject to change without notice.

This user’s manual documents product features, hardware, and controls software available at the time this user's manual was published.

Page iiiDukane Manual Part No. 403-608-00

Revision History

Revision RevisionNumber Summary Date

- 00 Original release. June 13, 2019

Page iv



This page intentionally left blank

Page vDukane Manual Part No. 403-608-00

Contents

Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1

Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 7

Section 3- Installation . . . . . . . . . . . . . . . . . . . . . . . 13 Connecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Section 4 - System Operation . . . . . . . . . . . . . . . . . 19 iQ Auto-Plus System Operational Test. . . . . . . . . . . . . . . . . . . . . . . .22 LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Section 5 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Distance Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Section 6 - Automation Interface . . . . . . . . . . . . . . 31 E-Stop Wiring and Automation System Safety Circuit . . . . . . . . . . . . 33 iQLinQ™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Section 7 - Contacting Dukane . . . . . . . . . . . . . . . . 35

Section 8 - Specifications . . . . . . . . . . . . . . . . . . . . 39 Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Weight, Operating Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Interpreting the Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Section 9 - Appendices . . . . . . . . . . . . . . . . . . . . . . 47

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Page vi




Page 1

Section 1 – Introduction


SECTION 1Introduction

General User Information . . . . . . . . . . . . . . . . . . 3

Read The Manual First . . . . . . . . . . . . . . . . . . . . . . 3

Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . 3

Drawings and Tables . . . . . . . . . . . . . . . . . . . . . . . 3

Generator Overview . . . . . . . . . . . . . . . . . . . . . 4

Key Generator Features . . . . . . . . . . . . . . . . . . . 4

Thermal Considerations . . . . . . . . . . . . . . . . . . . 5

Page 2




Page 3



General User InformationRead This Manual FirstBefore operating your ultrasonic system, read this User’s Manual to become familiar with the equipment. This will ensure correct and safe operation. The manual is organized to allow you to learn how to safely operate this equipment. The examples given are chosen for their simplicity to il-lustrate basic operation concepts.

This manual provides information to set up, operate, and interface this generator/power supply.Particular models are listed in Section 7 - Specifications.

Notes, Cautions and WarningsThroughout this manual we use NOTES to provide infor-mation that is important for the successful application and understanding of the product. A NOTE block is shown to the right.

In addition, we use special notices to make you aware of safety considerations. These are the CAUTION and WARNING blocks as shown here. They represent increas-ing levels of important information. These statements help you to identify and avoid hazards and recognize the conse-quences. One of three different symbols also accompany the CAUTION and WARNING blocks to indicate whether the notice pertains to a condition or practice, an electrical safety issue or a operator protection issue.

CAUTIONCaution statements identify conditions or practices that could result in damage to the equip-ment or other property.

WARNINGWarning statements point out conditions or practices that could re-sult in personal injury or loss of life.

NOTENote statements provide additional information or highlight procedures.

Drawings and TablesThe figures and tables are identified by the section num-ber followed by a sequence number. The sequence num-ber begins with one in each section. The figures and tables are numbered separately. The figures use Arabic sequence numbers (e.g. –1, –2, –3) while the tables use Roman sequence numerals (e.g. –I, –II, –III). As an ex-ample, Figure 3–2 would be the second illustration in sec-tion three while Table 3–II would be the second table in section three.

Hearing Protection

Conditionor Practice

ElectricalSafety Issue

Page 4



Generator OverviewThis generator is designed for ultrasonic applications con-trolled by a Programmable Logic Controller (PLC). Us-ing one of the supported industrial protocols see iQLinQ™ section pg. 34, the generator can easily be integrated into a wide variety of automated systems. The generator has a variety of status LED indicators, and built-in USB and EtherNet connectors.The iQ Auto-Plus MPC combines an iQ Auto-Plus gen-erator and Dukane’s patented Multi-Probe Controller in a single unit. This allows the generator to power multiple probes selected by an automated control system. This product’s rugged internal ultrasonic generator cir-cuitry ensures a continuous resonant frequency lock at the start of each weld. Users can modify generator per-formance to meet a wide variety of ultrasonic processing requirements if needed.The generator’s compact size allows multiple units to be placed into an industrial equipment cabinet, and the gen-erator will operate at the same international line voltage input specifications as the other generators of this product family. It also includes an RFI line filter that passes strict CE test specifications for global applications.

Key Generator Features• Compact Enclosure Size requires a small footprint for

either vertical or horizontal mounting into your equip-ment cabinet.

• Pulse Width Modulation incorporates patented circuitry giving the power supply the ability to efficiently change the output amplitude. This makes it possible to start large horns with reduced power. It also provides more power efficient switch-mode gen-erator operation and increased reliability.

• Linear Ramp Soft Start circuitry allows the acous-tic stack to ramp up to operating amplitude smoothly, minimizing the startup surges and abnormal stress to the stack and generator.

• Automatic Tuning tracks the resonant frequency of the acoustic stack (horn, booster, transducer) and ad-justs the generator output frequency to match it. This is done for every weld cycle and eliminates the need to manually tune the generator.

• Line Voltage Regulation automatically maintains constant amplitude regardless of line voltage devia-

tion. The available output power is maintained with any voltage input within the specified range. This provides consistent system performance regardless of line voltage fluctuations. It also eliminates the need for bulky, external constant–voltage transformers.

• Load Regulation provides constant amplitude auto-matically regardless of power draw. The ultrasonic output amplitude level is held to within ±1% to pro-vide weld process consistency and reduced weld cycle times.

• Universal AC Power Source means that standard systems will operate worldwide at all industrial high line voltage levels, whether it is 100-200VAC @60Hz in Japan, 240VAC @50Hz in Europe or 100-240VAC @60Hz in the United States. There are no internal transformer taps to change for worldwide operation.

• Amplitude Adjustment Control allows the peak -to-peak excursion of the horn at its workface to be ad-justed between 20% and 100% of the horn’s nominal amplitude.

• Multiple Electronic Overload protection circuits prevent instantaneous component failure in the event of extreme output overload conditions and rated over-load power limit is based on the actual true RMS power output level.

• Integrated MPC allows sequencing up to eight ultra-sonic probes. Each probe is independently controlled and monitored allowing different process settings and indepedent suspect or bad part alarms for each weld point.

• Optional Weld by Distance Feature to monitor up to eight analog 0-10 VDC encoders (requires customer supplied encoders).

• CE Certification means that the system meets the required European standards to be sold and used in Europe.

• ISO Certified means that this system has been manu-factured to high quality standards and assures you of manufacturing excellence.

• TUV Certification - TÜV Rheinland certifies Dukane products comply with applicable UL (Underwriters Laboratories) and CSA (Canadian Standards Associa-tion) requirements.

Page 5



Thermal ConsiderationsThe thermal design of this generator is for applications that require 100% of rated power at no more than a 50% duty cycle.

NOTE Add transducer cooling as necessary to keep front mass temperature to 110°F or less.

Page 6




Page 7

Section 2 – Health and Safety


SECTION 2Health and Safety

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Power Grounding Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Page 8




Page 9



Proper Installation - Operate system components only after they are properly installed.

No Unauthorized Modifications - Do not modify your system in any way unless authorized to do so by Dukane. Unauthorized modifications could cause equipment dam-age and/or injury to the operator. In addition, unauthorized modifications will void equipment warranty.

Keep the Cover On - Do not remove any equipment cover unless directed to do so by Dukane. The genera-tor produces hazardous electrical voltages which could cause injury.

Grounded Electrical Power - Operate this equipment only with a grounded electrical connection.

See Electrical Safety for grounding instructions, Page 10.

Comply with Regulations - You may be required to add accessories to bring the system into compliance with applicable regulations (OSHA in the USA) for machine guarding and noise exposure.

Use Eye Protection - Wear ANSI approved safety impact goggles.

Acoustic Stack Hazard - When an acoustic stack (trans-ducer, booster, horn and tip) is energized by the ultrasound signal, it presents a potential hazard. Stay clear of an energized stack.

System E-STOP (abort) Switch - Install a system E-STOP (abort) switch at each operator station when ultra-sonic plastic assembly equipment is used with automatic material handling equipment in an automated system.

Foot Switch - Do not use a foot switch. Using a foot switch in place of the optical touch finger switches (oper-ate switches) violates OSHA regulations. Do not install a foot switch.

NOTEThese recommendations apply to the welding system. System in this manual refers to a complete group of components associated with the welding of parts, also known as an ultrasonic assembly system. A typical iQ Series System consists of the iQ generator, a press with thruster, switch-es, controls, cables, transducer, booster, horn, and fixture, and iQ Explorer II software.

CAUTIONAt some time you may be asked to remove equipment covers by the Dukane Service Dept. personnel. Before doing so,

disconnect the unit electrically from the in-coming line AC power. If the unit is a press/thruster, lock the Air Lockout Valve, located on the rear panel, in its closed position.

General ConsiderationsPlease observe these health and safety recommenda-tions for safe, efficient, and injury-free operation of your equipment.

Never operate the genera-tor with the cover off . This is an unsafe practice and may cause injury .

Any fixture manufactured by a third party must com-ply with all OSHA and ANSI

requirements. All fixtures must be guarded as necessary .Dukane does not assume any responsibility or liability for fixtures manufactured by the customer or any third party manufacturer .

WARNING

Continued

WARNING

Page 10



System Electrical Cabling - Electrical power must be off when connecting or disconnecting electrical cables.

Do Not Wear Loose Clothing or Jewelry - They can become caught in moving parts.

Stay Alert - Watch what you are doing at all times. Use common sense. Do not operate the equipment when you are tired or distracted from the job at hand.

Do Not Operate the Equipment - Your judgement or reflexes could be impaired while taking prescription medi-cations. If so, do not operate the equipment. Be familiar with warning labels and recommended activity restrictions that accompany your prescription medications. If you have any doubt, do not operate the equipment.

General Considerations

Plastics Health NoticeCertain plastic materials, when being processed, may emit fumes and/or gases that may be hazardous to the operator’s health. Proper ventilation of the work station should be provided where such materials are processed. Inquiries should be made to the U.S. Department of Labor concerning OSHA regulations for a particular plastic prior to processing with Dukane ultrasonic equipment.

Electrical SafetyThe iQ Series generator provides the operating power and power returns. Make sure the generator is grounded properly.

In addition to the safety considerations, proper grounding is essential for the effective suppression of RFI (Radio Frequency Interference). Every generator contains a RFI filter which blocks noise on the AC power line from enter-ing the generator control circuitry. This filter also prevents ultrasonic RFI from being fed back into the AC power line.

Always connect the included ground wire from the PE ground of the generator to the nearest grounded metal pipe or equivalent earth ground by means of a ground clamp.

Continued from Previous Page

CAUTION

CAUTIONParts being joined ultrasoni-cally will at times vibrate at audible frequencies. Wear ear protectors to reduce annoy-ing or uncomfortable sounds.

In addition, ultrasound baffles, sound en-closures, or materials that absorb sound may be located to surround the system.

When making cable connec-tions to system equipment or disconnecting cables from system equipment,

make sure electrical power to the system is turned off, and AC power cords are removed from their receptacles. After the cables have been securely connected and the connections and cable routing checked a final time, the power may be restored.

Page 11



Electrical SafetyPower Grounding ConnectionFigure 2-1 illustrates how the AC line is connected to the iQ Auto Plus generator.

Figure 2–1 AC Line Connection

If there is any question about grounding of your e q u i p m e n t a n d / o r i t s electrical power source,

contact a quali f ied electr ician.

TerminalWire Color

North America EuropeL (Live) Black Lt. Brown

(Ground) Green Green w/yellow stripe

N (Neutral) White Lt. Blue

Table 2-I Conventional Wire Color Code

LN

iQ Auto Plus Power Inlet

Pluggable AC Line Connector

For safe system operation: To avoid the risk of fire, electri-cal shock, serious injury or death, the power line safety ground must be securely

connected to the center terminal on the (pluggable) AC line connector.

CAUTION

CAUTION

Page 12




Page 13

Section 3 – Installation


SECTION 3Installation

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Chassis Grounding Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Basic Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Page 14




Page 15



UnpackingCarefully open your shipping container, and make sure it contains the items shown on the shipping documents. Inspect all items, and report any missing items or damage immediately.

PlacementMake certain generator placement and cable routing do not interfere with normal operation. Maintain easy access to your equipment.

The operator should have unobstructed access to cables and wiring. Two sets of removable mounting brackets are attached to the generator. See Figure 3-1, below. Use them to securely mount the unit vertically or horizontally in your equipment cabinet.If the generator is installed inside an enclosure with a door, be sure there is adequate clearance for the system cables with the door closed.

Placement in a Seismic RegionIf the iQ generator is to be used in an active seismic region, secure the unit by rack-mounting it or by securing the unit to a benchtop.

Refer to Dukane’s website for more information about installation in a seismic zone. See Application Note 511 - http://www.dukane.com/us/DL_ApplData.asp

NOTEHeat Dissipation - Provide enough air flow for heat dissipation. For best heat dis-sipation, mount the generator vertically.

NOTEFor equipment weights see Page 42, in Section 8, Specifications.

Mounting Bracket

Figure 3-1 Generator Mounting Bracket

https://documents.dukane.com/AppNote/An511.pdf

Page 16



Power GroundingFor safety, the iQ Auto chassis must be properly ground-ed. The power line ground connection is located on the center screw terminal on the AC Power Inlet pluggable screw terminal connector.This system ground connection must be attached to an earth ground potential at the electrical box that supplies power to the enclosure or cabinet in which the iQ Auto system is installed.The ground connection should comply with all of the re-quirements specified by the National Electrical code and any other local codes or ordinances that are applicable.

Chassis Grounding StudProper grounding for the generator chassis is essential for the effective suppression of electrical noise or RFI (Ra-dio Frequency Interference). Every ultrasonic generator contains a RFI filter that blocks noise on the AC power line from entering the system control circuitry. This filter also prevents ultrasonic frequency noise from being fed back into the AC power line. For the RFI filter to operate effectively, it is necessary to correctly ground the system. The power line ground previously mentioned is manda-tory.Additionally, the included grounding wire must be con-nected from the grounding stud connection (see Figure 3-1) to the nearest grounded metal pipe or equivalent earth ground.This will improve the chassis ground connection and may be needed in noisy industrial environments.See Connecting Cables on the next page.

CAUTIONTo minimize electrical noise and eliminate ground cur-rents, ground the chassis as shown. Use a STAR configu-ration (shown below).Do not DAISY CHAIN the grounds.

EarthGround

#14 Gauge Stranded orSolid Wire

Fixed Probe Mount or 2nd ChassisGrounding Stud

3rd Chassis GroundingStud

Chassis GroundingStud

Protective earth ground connection wire color: green or green with yellow stripe.

NOTEChassis Grounding StudThe chassis grounding stud is used to attach a protective earth ground to the generator. This helps suppress electrical interference or radio frequency interfer-ence (RFI) that is common in an industrial environment. Stud location is shown in Figure 3-2 on the following page.

CAUTIONIf you have any questions about the grounding of your equipment and/or the electri-cal box, contact a qualified electrician.

Page 17



Connecting CablesBasic ConnectionsComplete these basic connections for the standard con-figuration as shown below:

• AC Line Input

• iQLinQ™

• Ultrasound Outputs

• Grounding Details about the various system connectors and their pin assignments are covered in the next section.1. Wire the AC line connector, and attach it to the gen-

erator’s power inlet connector, matching the power source line, ground, and neutral with the generator’s line, ground, and neutral connector pins - A in Figure 3–4. (See Figure 2-1 also.)

2. Connect the appropriate cable from the PLC to the Ethernet/IP Modbus - B in Figure 3-2, or ANYBUS module port for iQLinQ™ control of the generator.

3. Attach high–voltage coaxial ultrasound cables (from the ultrasonic probes) , the ultrasound output connec-tors - C in Figure 3-2.

4. Connect the included ground wire from the grounding stud, D in Figure 3-2, to earth ground.

5. Connect the included E-STOP terminal block to a switch or jumper the two connections together ( E in Figure 3-2). Plug the terminal block into the E-Stop port.

Figure 3-2 Generator Front View

NOTEAC Power InletLine voltage required for the generator is 100-240VAC at 50/60 Hz and 15 Amps Maximum.The unit does not include a power switch, and is powered ON whenever the AC line power is live. The unit can be switched ON/OFF with a user-supplied AC circuit breaker wired to the AC power inlet connection.

NOTEConnecting CablesTwo-piece pluggable terminal block con-nectors are used for the the AC Power Inlet connections.This type of connector allows the wiring to be attached to the spring loaded terminal connector, which plugs into the mating con-nector on the iQ Auto system front panel.In the event a field replacement unit is required, the terminal connectors with the wires can be easily detached and then plugged into the replacement unit.

See NOTE on Page 18 .

Grounding Stud

E-STOP

Power Inlet

D

Ethernet/IP Modbus port

BA

E U/S Connectors

C

Page 18



NOTE

Ultrasound Output ConnectorThe ultrasound output connector used with all standard generators is a high voltage (5000V) coaxial style SHV-BNC connector. This connector provides superior shielding of electri-cal noise, compared to other types of connectors. The ultrasound output connector mates with fully shielded coaxial ultrasound cables that are secured with a simple and reliable quarter-turn bayonet style attachment mechanism.

The ultrasonic output from this con-nector (that drives the attached ultrasonic load) is a very high AC volt-age (1200VAC). At high power levels this can exceed 2 amps of current and must be securely terminated via the ultrasound cable for safe operation. Use original equipment ultrasound cables for safe and reliable system operation. Improperly assembled ultrasound cables can result in high voltage arcing and will destroy the ultrasound connectors.

Page 19

Section 4 –System Operation


SECTION 4System Operation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

iQ Auto-Plus System Operational Test . . . . . . . . . . . . . . . . . . 22

LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Page 20




Page 21



IntroductionThe ultrasonic iQ Auto-Plus generator/power supply, is specifically designed to meet the machine builder’s requirements. This unit is automation ready and has the capability of controlling up to 8 probes.The generator’s USB, Ethernet, and optional ANYBUS ports extend communication and control functions depending on the specifications of a particular generator model.

This section deals primarily with basic operational testing and troubleshooting.

Page 22



iQ Auto-Plus System Operational Test1. Verify that the standard system installation is complete

and all cables are connected.

Refer to installation instructions included in Section 3, if needed.

2. After completing Step 1, activate line power to the iQ Auto-Plus system.

Normal Condition:

GREEN - The POWER and STATUS LEDs on the iQ Auto-Plus panel should both light up GREEN.

The system is now ready to operate.

Troubleshooting Abnormal iQ Auto-Plus System Conditions

POWER LEDRED - If this LED lights up RED, check line voltage level. GRAY - If this LED is a gray color (not lit), check line input.

3. After completing Step 2, test ultrasound output by using iQLinQ™ or iQ Commander™

Normal Condition:

The system is operating properly when power is delivered to the attached stack.

4. Check the operational Status LED

Figure 4-1 Generator POWER LED Detail

An Overload Fault latches until the next time U/S is activated.

Any Fault status activates when any fault is de-tected by the system. It latches until the start of the next cycle, unless it is activated due to Overtemperature or Power Not OK fault.

Five fault conditions are monitored by the iQ Auto-Plus system for Any Fault:

• Average Overload(Automatically resets on next cycle)

• Peak Overload(Resets same as Average Overload)

• Overtemperature(Automatically resets on cool-down)

• Power Not OK(AC line voltage under minimum voltage)

• Frequency Overload (Automatically resets on next cycle)

• Over Voltage Overload (Automatically resets on next cycle)

POWER LED

Continued

PROBE STATUS LED

STATUS LED

Page 23



PROBE STATUS LED

STATUS LED

5. Check MPC Channels

Check that all MPC channels can be selected and activated. The automation control system activates input selection bits.

Select a channel: PROBE SELECTION STATUS indicator illuminates GREEN when it is the selected channel.

Activate ultrasound: Activate the iQ Auto-Plus ul-trasound output. The PROBE SELECTION STATUS indicator on the selected channel should switch to RED (from GREEN).

The probe on the selected channel should deliver ultrasonic power.

Repeat this test for all MPC channels.

Page 24



LED Indication There are seven LEDs on the iQ Auto-Plus generator: - POWER (1) - ETHERNET (2) - MOD (1) - NET (1) - STATUS (1) - PROBE SELECTION (2, 4, 6, or 8)

Figure 4-2 shows LED location, and Table 4-I shows their indications.

Figure 4-2 LED Locations

POWER

ETHERNET

MOD

STATUS

NET

PROBE SELECTION(STATUS LED)

Page 25



LED COLOR INDICATION

POWER Gray Off - No power.

Green - Steady Power on. Red - Steady Voltage problem. Check line voltage level.

ETHERNET

Left - Speed IndicatorAmber - Steady On - Operating as a Gigabit connection (1000 Mbps)Green - Steady On - Operating as a 100-MBPs connection.

Off Operating as a 10-Mbps connection.

Right - Activity IndicatorYellow - Blinking There is activity.

Off No activity.

MOD

Red - Steady Unrecoverable FaultRed - Blinking Minor Fault

Green - Steady Device OperationalGreen - Blinking Standby

Gray Off - No power.

NET

Red - Steady Duplicate IP (Not Supported)Red - Blinking Connection Time Out

Green - Steady ConnectionGreen - Blinking No Connection

STATUS

Green - Steady ReadyYellow - Steady E-STOP ActiveOrange - Steady In Cycle

Red - Steady Average OverloadRed - Blinking Peak Overload

Orange - Blinking Voltage OverloadBlue - Steady Overload - Frequency Failed

Light Blue - Steady Overload - Frequency LostYellow - Blinking Power Fault

PROBE STATUSGray OFF - Not Selected

Green ON - SelectedRed Selected and Ultrasound Active

Table 4-I LED Colors and Indication

Page 26




Page 27

Section 5 – Options


SECTION 5Options

Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Distance Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Page 28




Page 29

Section 5 – Options


Figure 5-1 Generator with Heat Sink Option

Heat SinkThe thermal design of 600 watt generators is for applications that require a power of 600 watts or less at duty cycles less than 50%.

For applications that require higher duty cycles, an optional cooling package is available. The Dukane Part Number for the package is 438-1020.

The cooling package is standard on 1200 watt models and includes a heat sink that mounts to the generator as shown in Figure 5-1 below.

When operating an iQ Auto-Plus MPC generator with the optional heat sink, do so with the generator in the vertical position as shown in Figure 5-1. Air flow is enhanced, and the heat sink’s efficiency is maximized.

CAUTIONOperate the iQ Auto-Plus generator in the vertical po-sit ion as shown in Figure 5-1. This allows for optimal air circulation enabling the heat sink to be most effective.

Heat Sink

Air

Flo

w

Page 30



Distance OptionThe weld by distance feature can monitor up to eight analog 0-10 VDC encoders. A maximum of one customer supplied encoder for each MPC channel. See https://documents.dukane.com/AppNote/AN528.pdf for more information.

https://documents.dukane.com/AppNote/AN528.pdf

https://documents.dukane.com/AppNote/AN528.pdf

Section 6 – Automation Interface

Page 31Dukane Manual Part No. 403-608-00

SECTION 6Automation Interface

E-STOP Switch Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Automation System Safety Circuit . . . . . . . . . . . . . . . . . . . . . . . 33

iQLinQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

TM

Page 32




Section 6 – Automation Interface


Figure 6-1 E-STOP Wiring and Automation System Safety Circuit

iQ Auto-Plus MPC

Enable Out

Enable In

Dedicated E-Stop Switch Wiring DiagramE-STOP Connector

(Pin 1)

(Pin 2)

User suppliedE-stop switch

Enable Out

Enable In

Automation System Safety Circuit Wiring DiagramE-STOP Connector

(Pin 1)

(Pin 2)

User automation control hardware

Master control relay

Relay contact block

iQ Auto-Plus MPC

Page 34



iQLinQ™ communication options allow automated systems to monitor and change settings in iQ generators. These options provide machine builders the ability to integrate the generator into an electrical cabinet and to use the machine’s HMI to program or monitor weld settings.

All iQ Auto-Plus MPC generator includes iQLinQ™ EtherNet/IP and Modbus TCP/IP communication protocol support. Using one of these protocols avoids adding expensive analog cards into PLC racks. iQLinQ™ is available for PROFIBUS, PowerLink, Profinet, EtherCAT, and CC-Link with the optional ANYBUS module.

iQLinQ™ Demos are available to provide complete ladder logic and HMI screens that can be dropped into Allen Bradley (RSLogix 5000; Studio 5000 Logix Designer; Factory View Studio ME) Siemens (TIA Portal) and B&R (Automation Studio) PLC projects.Contact your local Dukane representative for more information about the iQLinQ™ options.

iQ LinQ™ The iQLinQ™ allows the iQ generator to connect to an industrial network.

Control Parameters available via iQLinQ™

1. Set weld method to Time, Energy, Peak Power, Dis-tance, and/or Position. Set associated values in seconds, joules, watts, or millimeters/inches.

2. Set Amplitude, Ramp Up Time, and Ramp Down Time.

3. Enable and set Trigger by Power or Trigger By Position parameters.

4. Enable and set Hold time.

5. Enable and set Afterburst delay and duration.

6. Enable checking for Suspect Parts. Set maximum and minimum values for Time, Power Energy, Distance, and/or position.

7. Enable checking for Bad Parts. Set maximum and minimum values for Time, Power, Energy, Distance, and/or Position.

8. Configure advanced hardware settings including Fre-quency Tracking, Free Run Frequency, Frequency Lock and Hold, and Frequency limits.

Control Parameters Available via iQLinQ™

1. All parameters that are configured via iQLinQ™.

2. Real time data which includes welder state (ultrasound active or not), frequency, power, amplitude, and position.

3. Weld cycle data from previous weld which includes:

• Cycle Count

• Good, Bad, and Suspect Part information

• Process Limit setting exceeded or not reached if Bad or Suspect Part checking is enabled

• Weld Time

• Weld Energy

• Peak Power

• Weld Distance

• Weld End Position

For information on how to control and/or monitor specific pa-rameters, iQ Generator iQLinQ™ Communication and Control documentation is available.

Signing a non-disclosure agreement is required to obtain this documentation.

™

Section 7 – Contacting Dukane


SECTION 7Contacting Dukane

Page 36




Section 7 – Contacting Dukane


Contacting DukaneIdentify EquipmentWhen contacting Dukane about a service–related problem, be prepared to give the following information:

• Model number, line voltage and serial number.

• Fault status.

• Problem description and steps taken to resolve it.

Many problems can be solved over the telephone, so it is best to call from a telephone located near the equipment.

Mailing Address: Dukane 2900 Dukane Drive St. Charles, IL 60174 USA

Phone: (630) 797–4900

E-mail: [email protected]

Fax: Main (630) 797–4949 Service & Parts (630) 584–0796

WebsiteThe website has information about our products, processes, solutions, and technical data. Downloads are available for many kinds of literature.

Here is the address for the main website: www.dukane.com

You can locate your local representative at: www.dukane.com/contact-us/


http://www.dukane.com/contact-us/

Page 38




Section 8 – Specifications


SECTION 8Specifications

Generator Outline Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Operating Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Interpreting the Model Number. . . . . . . . . . . . . . . . . . . . . . . . 44

Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . 45

Page 40






PICTO

RIA

L VIEW:

SCA

LE 2 / 3PO

WER

INLET

100-240 VAC

MAXIM

UM

(8) PRO

BES

9.12[232]

.88[22]

.85[22]

OPTIO

NAL

BOTTO

M

HEAT SIN

KAN

D M

OU

NTIN

GFEET

9.25[235]

9.50[241]

ALLOW

3.00" [76] FO

R C

ABLEC

ON

NEC

TOR

11.25[286]

10.73[273]

10.61[269]

9.85[250]

7.38[187]

4.50[114]

.75[19]

6.00[152]

.69[18]

.89[22]

2.00[51]

LOW

ERM

OU

NTIN

G

BRAC

KETS

11.25[286]

DISTAN

CE C

ON

NEC

TOR

1.78[45]

BOTTO

M R

EARM

OU

NTIN

G BR

ACKET

10.38[264]

9.50[241]

USB 2.0

ETHER

NET

ANYBU

S CO

NN

ECTIO

N

2.00[51]

5.11[130]

4.15[105]

.72[18]

1.78[45]

TOP R

EARM

OU

NTIN

G BR

ACKET

BASE MO

UN

TING

BRAC

KETS (2)

Figure 8-1 Generator Outline Drawing

Page 42



Operating EnvironmentOperate the generator within these guidelines:Temperature: 40°F to 100°F (+5°C to +38°C)Air Particulates: Keep the equipment dry. Minimize exposure to moisture, dust, dirt, smoke and mold.Humidity: 5% to 95% non–condensing @ +5°C to +30°C

Nonoperating storage guidelines:Temperature: -4°F to 158°F (-20°C to +70°C)Air Particulates: Keep the equipment dry. Minimize exposure to moisture, dust, dirt, smoke and mold.Humidity: 5% to 95% non–condensing @ 0°C to +30°C

WeightStandard Model: 16 pounds (7.26 kg)

Shipping: Add 5 pounds (2.3 kg) to unit weight for packing materials.



AC Power Requirements

Table 8-I AC Power Requirements

OperatingFrequency

Generator Model Number

Overload PowerRatings (Watts)

Input AC Power RequirementsNominal AC Volt

@ Maximum RMS Current

20kHz 20AM060-UF-CX-XX 600 100-240V 50/60 Hz @ 15 Amps Max

20kHz 20AM120-2F-CX-XX 1200 200-240V 50/60 Hz @ 15 Amps Max







Page 44



iQIntegrated M

PC Probe Generator Model N

umber Codes

30

Nom

inalU/S Frequency

20= 20 kH

z30 = 30 kH

z35 = 35 kH

z40 = 40 kH

z50

=50

KH

z

AM

Chassis Style –

Power Sw

itch Configuration

AM = Auto Series W

ith integrated MPC Panel M

ount Chassis (Non-Autom

otive)ST = Auto Series W

ith integrated MPC Panel M

ount Chassis (Automotive)

Power Level

120 = 1200 Watts

060 = 600 Watts

040=

400W

atts

10

22

AC Line Input

2 = 200-240 for 1200WU

= 100-240V for 600 W

System Process C

ontrol

FC

5

Options Slot #1

C1 = iQLinQ

™ PRO

FIBUS Interface M

odule C2 = iQ

LinQ™

Ethernet/IP InterfaceC3 = iQ

LinQ™

PROFIN

ET Interface Module

C4 = iQLinQ

™ CC-Link Interface M

odule C5 = iQ

LinQ™

POW

ERLINK Interface M

odule C6 = iQ

LinQ™

EtherCATInterface M

odule C7 = iQ

LinQ™

Modbus TCP Interface

Example System

Num

ber shown above:

30AM120-2F-C5-02

System Assem

bly Detailed Description:30kHz 1,200 W

att System operates on a 200-240V AC Line w

ith a POW

ERLINK com

munications m

odule and two point M

PC installed. 1200W

is only available in 30K and 35K units and 400W is only available in 50K m

odels.

Probe System O

ptionsF = Auto Plus w

/iQLinQ

™ Advanced com

munication Support

Without D

istance02 = 2 P

robes04 = 4 P

robes06 = 6 P

robes08 = 8 P

robes

With D

istanceD

2 = 2 Probes

D4 = 4 P

robesD

6 = 6 Probes

D8 = 8 P

robes

Num

ber of Probes

02

Interpreting the Model Number

Figure 8-2 Interpreting the Model Number



Regulatory Agency Compliance FCCThe generator complies with the following Federal Com-munications Commission regulations.• The limits for FCC measurement procedure MP-5,

“Methods of Measurement of Radio Noise Emissions from ISM Equipment”, pursuant to FCC Title 47 Part 18 for Ultrasonic Equipment.

CE MarkingThis mark on your equipment certifies that it meets the requirements of the EU (European Union) concerning interference causing equipment regulations. CE stands for Conformité Europeéne (European Conformity). The equipment complies with the following CE requirements.• T h e E M C D i r e c t i v e 2 0 0 4 / 1 0 8 / E C

for Heavy Industrial — EN 61000-6-4: 2001

EN 55011: 2003 EN 61000-6-2: 2005 EN61000–4–2

EN61000–4–3 EN61000–4–4 EN61000–4–5 EN61000–4–6 EN61000–4–8 EN61000–4–11

• The Low Voltage Directive 2006/95/EC.

• The Machinery Directive 2006/42/EC. EN 60204: 2006 Safety of Machinery - Electrical Equipment of

Machines Part 1: General Requirements.

IP RatingThe iQ generator has an IP (International Protection) rating from the IEC (International Electrotechnical Commission).The rating is IP2X, in compliance with finger-safe industry standards.

ULThe iQ generator complies with these standards:Underwriters Laboratories:UL 1012: 2010UL 61010-1:2012, and

National Standards of Canada:CAN/CSA C22.2 No. 61010-1-12:2012

as verified by TÜV Rheinland.

CAUTIONDO NOT make any modi-fications to the generator or associated cables as the changes may result in violating one or more regulations under which

this equipment is manufactured.

Page 46




Section 9 – Appendices


SECTION 9

Appendices

Appendix A, List of Figures. . . . . . . . . . . . . . . . . . . . . 49

Appendix B, List of Tables . . . . . . . . . . . . . . . . . . . . . 50

Page 48




Section 9 – Appendices


List of FiguresNo. Description Page

Appendix A

2-1 AC Line Connection ......................................................................................................11

3-1 Generator Mounting Bracket .........................................................................................153-2 Generator Front View ....................................................................................................17

4-1 Generator POWER LED Detail .....................................................................................224-2 LED Locations ...............................................................................................................24

5-1 Generator with Heat Sink Option ...................................................................................29

6-1 E-STOP Wiring and Automation System Safety Circuit .................................................33

8-1 Generator Outline Drawing ............................................................................................418-2 Interpreting the Model Number ......................................................................................44

Page 50



Appendix B List of TablesNo. Description Page

2-I Conventional Wire Color Code .......................................................................................11

4-I LED Colors and Indication ..............................................................................................25

8-I AC Power Requirements ................................................................................................43

Index


Index

Page 52




Index


Index

AAgency Compliance 45

CE Marking 45

FCC 45

IP (International Protection) Rating 45

Appendices 47

Appendix A - List of Figures 49

Appendix B - List of Tables 50

Automation Interface 31

CChassis Grounding Stud 16

Connecting Cables 17

DDukane

Email 37

Phone 37

Service and Parts 37

www.dukane.com 37

EElectrical Safety

Power Grounding Connection 11

FFCC 45

GGeneral User Information 3

Drawings and Tables 3

Notes, Cautions and Warnings 3

Read This Manual First 3

Generator

Features 4

Overview 4

Thermal Considerations 5

HHealth and Safety

Electrical Safety 10

General Considerations 9

Plastics Health Notice 10

Recommendations 9

Heat Sink 29

IInstallation

Connecting Cables 17

Placement 15

Placement in a Seismic Region 15

Power Grounding 16

Unpacking 15

Interpreting the Model Number 44

IP (International Protection) Rating 45

iQLinQ™ 34

NNotes, Cautions and Warnings 3

Page 54



OOptions

Distance Option 30

Heat Sink 29

RRegulatory Agency Compliance 45

SSpecifications

AC Power Requirements 43

Interpreting the Model Number 44

Operating Environment 42

Weight 42

System Operation

Introduction 21

iQ Auto-Plus System Operational Test 22

LED Indication 24

TThermal Considerations 5

Dukane ISOISO CERTIFICATIONDukane chose to become ISO certified in order to demonstrate to our customers our continuing commitment to being a quality vendor. By passing its audit, Dukane can as-sure you that we have in place a well–defined and systematic approach to quality design, manufacturing, delivery and service. This certificate reinforces Dukane's status as a quality vendor of technology and products.

To achieve ISO certification, you must prove to one of the quality system registrar groups that you meet three requirements:1. Leadership2. Involvement3. Quality in Line Organizations and Qual-

ity System Infrastructure.

The ISO standards establish a minimum re-quirement for these requirements and starts transitioning the company from a traditional inspection–oriented quality system to one based on partnership for continuous improve-ment. This concept is key in that Dukane no longer focuses on inspection, but on indi-vidual processes.

Dukane's quality management system is based on the following three objectives:1. Customer oriented quality. The aim is to

improve customer satisfaction.2. Quality is determined by people. The

aim is to improve the internal organi-zation and cooperation between staff members.

3. Quality is a continuous improvement. The aim is to continuously improve the internal organization and the competi-tive position.

View the Dukane ISO certificate of compliance at: https://documents.du-kane.com/Certifications/ISO-Cert.pdf

Dukane products are manufactured in ISO registered facilities

https://documents.dukane.com/Certifications/ISO-Cert.pdf

https://documents.dukane.com/Certifications/ISO-Cert.pdf

Part No. 403-608-00

Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900

iQ Series, Ultrasonic Generator/Power SupplyAuto-Plus MPC User's Manual

Printed in the United States of America

www.dukane.com

Please refer to our website at:

www .dukane .com/contact-us/

to locate your local representative.


https://www.dukane.com/contact-us/

Documents

ULTRASONIC GENERATOR/POWER SUPPLY Auto-Plus MPC · This product’s rugged internal ultrasonic generator cir-cuitry ensures a continuous resonant frequency lock at the start of each